Systems for negative 3D printing machine at high resolution

ABSTRACT

Methods and apparatus for the fabrication of solid three-dimensional objects from liquid polymerizable materials at high resolution. A material is coated on a film non-digitally, excess material is removed digitally, by laser, leaving an image of a layer to be printed, and the image is then engaged with existing portions of an object being fabricated and exposed to a non-digital UV curing light source. Since the only part of the process that is digital is the material removal, and this part is done by laser, the speed of printing and the robustness of the manufacturing process is improved significantly over conventional additive or 3D fabrication techniques.

RELATED APPLICATIONS

This application is a Divisional of U.S. application Ser. No.17/248,220, filed on 14 Jan. 2021 (now issued as U.S. Pat. No.11,207,830), which is a NONPROVISIONAL of, and claims priority to U.S.Provisional Application No. 62/704,446, filed 11 May 2020, both of whichare incorporated herein by reference.

FIELD OF THE INVENTION

The present invention concerns methods and apparatus for the fabricationof solid three-dimensional objects from liquid polymerizable materialsat high resolution.

BACKGROUND

In conventional additive or three-dimensional fabrication techniques,construction of a three-dimensional object is performed in alayer-by-layer manner. Layer formation is performed throughsolidification of photo-curable resin under the action of visible or UVlight irradiation. Two techniques are known: one in which new layers areformed at the top surface of the growing object; the other in which newlayers are formed at the bottom surface of the growing object.

If new layers are formed at the top surface of the growing object, thenafter each irradiation step the object under construction is loweredinto the resin “pool,” a new layer of resin is coated on top, and a newirradiation step takes place. An example of such a technique is given inHull, U.S. Pat. No. 5,236,637. A disadvantage of such “top down”techniques is the need to submerge the growing object in a deep pool ofliquid resin and reconstitute a precise overlayer of liquid resin beforea next layer of the object can be formed.

If new layers are formed at the bottom of the growing object, then aftereach irradiation step the object under construction must be separatedfrom the bottom plate in the fabrication well. An example of such atechnique is given in Hull, U.S. Pat. No. 5,236,637. While such “bottomup” techniques hold the potential to eliminate the need for a deep wellin which the object is submerged by instead lifting the object out of arelatively shallow well or pool, a problem with such “bottom up”fabrication techniques, as commercially implemented, is that extremecare must be taken, and additional mechanical elements employed, whenseparating the solidified layer from the bottom plate due to physicaland chemical interactions therebetween. For example, in U.S. Pat. No.7,438,846, an elastic separation layer is used to achieve“non-destructive” separation of solidified material at the bottomconstruction plane. Other approaches employ a sliding build plate, forexample as shown in U.S. Pat. No. 9,636,873. Such approaches introduce amechanical step that may complicate the apparatus, slow the method,and/or potentially distort the product.

Continuous processes for producing a three-dimensional object aresuggested at some length with respect to “top down” techniques in U.S.Pat. No. 7,892,474, and the best approach to this date is offered by WO2014/126837. There, an interface between the first and second layers orzones of the same polymerizable liquid are formed. The first layer orzone (sometimes also referred to as a “dead zone”) contains an inhibitorof polymerization (at least in a polymerization-inhibiting amount); inthe second layer or zone the inhibitor has been consumed (or has nototherwise been incorporated or penetrated therein) to the point wherepolymerization is no longer substantially inhibited. The first andsecond zones do not form a strict interface between one another butrather there is a gradient of composition that can also be described asforming an interphase between them as opposed to a sharp interface, asthe phases are miscible with one another, and further create a(partially or fully overlapping) gradient of polymerization therebetween(and also between the three-dimensional object being fabricated, and thebuild surface through which the polymerizable liquid is irradiated).

Although promising, this technique has several limitations. First, itcan be used only for one material formulation at a time, limitingdramatically the physical properties of an article that can be producedby this technique. Second, the rate of production is limited by theinhibitor used, the viscosity of the liquid phase, and the UV lightsource power. Further, the article is still immersed in a resin bath andit needs to be cleaned at the end of the process to remove residuals.

SUMMARY OF THE INVENTION

Given the above-described limitations with current additive orthree-dimensional (“3D”) fabrication techniques, the current inventionprovides a much faster way to produce a three-dimensional article bycreating the next layer of the article being fabricated on a film at ahigh resolution and exposing it to a corresponding light source duringcontact between the film and previously formed portions of the article,to produce the formed article's next layer. Since this is a continuoussequence production process, the rate of object formation and itsversatility are improved over that of other techniques. Multiplematerials can be introduced at each layer and no cleaning is needed atthe end of the production process.

In one embodiment, a new method for 3D printing that reduces waste andenhances the speed of manufacturing is provided. A material is coated ona film non digitally, excess material is removed digitally, by laser,and a full image is then engaged with existing portions of the objectbeing fabricated (also referred to herein as a “sample”) and exposed toa non-digital UV curing light source. Since the only part of digitizingis the material removal, and this part is done by laser, the speed ofprinting and the robustness of the manufacturing process is improvedsignificantly over conventional additive or 3D fabrication techniques.

Among the materials that are most appropriate for the present approachare high viscosity materials that will not move between a materialjetting unit and a sample building unit, however, any material can beused while taking into account that as the material viscosity isreduced, the final resolution of the sample undergoing production isreduced as well.

One embodiment of a negative 3D printing system configured in accordancewith the present invention includes a coating system based on film androllers, a laser jetting system that is positioned on top of a materialreuse unit, and a sample building unit in which the film comes intocontact with a sample during UV curing. Another optional unit is asample release unit, which may operate using mechanical, chemical, oroptical (e.g., laser) means, or any combination of these approaches.

The coating system may be implemented in any of several fashions. Forexample, in one embodiment the coating system may include a syringe witha film forming unit in which a coated film passes between two rollers.Other coating approaches that can be used include traditional screenprinting, dispenser unit(s) printing, micro gravure coating, slot diecoating, inkjet printing, or roller coating.

The coating can be done in a controlled environment, e.g., to preventevaporation of solvent or oxidation and to minimize material waste forlater reuse, and in some embodiments implemented in a closed loop inwhich the material being coated on the film passes through a reuse unitwith small additions of material to previously unused portions thereofper cycle.

The coating system can, in some cases, support multiple material 3Dprinting.

The negative digital laser jetting system may include a pulsed laserwith enough energy to jet the negative image of the material from thefilm surface. Among possible lasers that can be employed for such apurpose are infrared (IR) lasers, ultraviolet (UV) lasers, carbondioxide (CO₂) lasers, etc.

The film that is used for transferring the material should be atransparent film, at least one that is transparent (or nearly so) to thewavelength of the laser being used, with or without a coating on thefilm. Examples of the transparent films that can be used arepolyethylene terephthalate (PET), biaxially-oriented polypropylene(BOPP), polyimide (PI), etc.

The coat of the film is used to enhance jetting of the material from thefilm to the material reuse system. To that end, a metal or other polymercoat with additives that adsorb at the laser wavelength and createtransparent areas digitally with exposure to the laser negative jettingsystem can be used.

As mentioned above, the materials portfolio that can be used for 3Dprinting with the present system is very wide and a detailed listing ofall of the possible materials is impractical. By way of example,possible materials can be UV/visible-light cured material formulationswith UV-cured monomers and polymers, viscose or sensitive materials,acrylates, epoxies, urethanes, adhesives, pastes, etc., and UV-curedmonomers and polymers with additives such as ceramics, metals, organicadditives, fiber reinforcement, etc., or UV-cured waxes.

The system can be used for low or high viscosity materials that arecured or partially cured by light and may also be used for materialsthat are cured by heat such as ceramic and metal pastes, solder pastes(epoxy-based or urethane-based), or silicone family materials with orwithout UV-curable ends. Reactions can advance by light, by heat, or byother catalyst (Pt, OH, etc.), or combinations of these mechanisms.

The system can be used also for highly sensitive material 3D printing,for example, 3D printing of bio-compatible materials. It could also beused for 3D printing of thermoplastic materials at room temperature orat elevated temperatures (with some adjustments).

The curing system used in embodiments of the system is not a digitalprocess and, therefore, a border range of curing means can be employed.For example, UV or visible light curing system can be used as can IR orother heat curing systems (as post treatments). It is also possible touse chemically latent catalysts for the curing reaction.

As one example, a basic UV formulation can use monomers and polymerslike acrylate, epoxy, urethane, and other UV or light sensitivematerials with light sensitive initiators or/and co-initiators orsensitizers, such as, acetophenones, thioxanthones, phosphine oxides,iodonium and sulfonium salts, etc.

The configuration of the sample release system may be dependent on thechemistry of the film, may involve some laser ablation or cleaning ofthe top surface after curing, and/or may be a mechanical system. Any ofseveral approaches can be used, for example, a system that provides alow angle release towards a Y-axis (e.g., by moving the film at smallangle away from the sample), or a system that provides two Z-axes, onefor a frame (holding the film) and one for the sample, or a system thatprovides an acoustic vibration to release the film from the sample.

These and other embodiments of the invention are described in detailbelow.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is illustrated by way of example, and notlimitation, in the figures of the accompanying drawings, in which:

FIG. 1 illustrates, in overview form, an embodiment of the invention,which includes coating a film with a material, removing excess materialinto a recovery system, and then exposing the coated film to anon-digital curing system (UV or heat based) during contact with thesample, thereby reducing waste and eliminating the need for supportmaterial.

FIG. 2 illustrates schematically a system configured in accordance withone embodiment of the invention, highlighting a coating process,negative printing with a material recovery unit, and curing duringcontact with a sample; an optional sample release unit is also shown.

FIGS. 3 a-3 m illustrate aspects of a process in accordance with anembodiment of the present invention, including negative jetting of amaterial (FIG. 3 a-3 c ) with optional initial curing (FIG. 3 d ),sample contact (FIG. 3 e-3 f ), curing (FIG. 3 g ), a release process(FIG. 3 h-3 j ), sample surface cleaning (FIG. 3 k ), and the overallresult and structure (FIG. 3 l-3 m ).

FIG. 4 illustrates an example of a system configured in accordance withpresent invention, with reels and rollers for coating a material on afilm and moving the film through a laser jetting unit towards samplecontact during exposure to UV light for curing.

FIG. 5 illustrates a further example of the system shown in FIG. 4 ,with several layers having been printed.

FIG. 6 illustrates yet a further example of the system shown in FIG. 4 ,with several layers having been printed with the optional addition of asupport material between layers.

FIG. 7 illustrates yet a further example of the system shown in FIG. 4 ,with several layers having been printed and including a support additionsystem configured for injection of the support material.

FIGS. 8 a and 8 b illustrate aspects of an embodiment of the inventionin which multiple materials are used during printing, both before (FIG.8 a ) and after (FIG. 8 b ) contact with the sample.

FIGS. 9 a and 9 b illustrate aspects of an embodiment of the inventionin which printing uses an anti-sticking foil to prevent sampledistortion during curing (FIG. 9 a ) and sample release (FIG. 9 b )processes.

FIG. 10 illustrates aspects of an embodiment of the invention in whichprinting includes using a mechanical release system to enable fast andaccurate sample building.

FIG. 11 illustrate aspects of an embodiment of the invention in whichprinting includes using a material recovery system to reduce the wasteof excess material during sample building.

DESCRIPTION OF THE INVENTION

The present invention concerns methods and apparatus for the fabricationof solid 3D objects from liquid polymerizable materials at highresolution. In one embodiment, a system configured in accordance withthe invention employs laser jetting of a negative image of an initialcoated film by polymerizable liquid at a high resolution, and exposureof the image to a corresponding light source during contact between thefilm and a sample to produce the sample's next layer. Since this is acontinuous sequence production process, the rate of 3D object formationand its versatility is improved over conventional 3D printing processes.Before describing the invention in detail, however, it is helpful topresent an overview. FIG. 1 provides such an overview, illustratingseveral constituents of a system 100 configured in accordance with theinvention: coating a film with a material 10, removal of excess materialinto a recovery system 12, and exposure of the coated film to anon-digital curing system (UV or heat based) during contact with asample 14.

By working with the negative picture of the desired image severalimportant key features of the current invention are revealed: First, anyexcess of material resulting from the coating process can be reused, andno significant waste is produced during the sample building process.Second, the need for support material is eliminated (although asdiscussed below, use of supporting material remains an option). Thenegative picture is supported by the film from its top side during thecuring and contact, thereby eliminating the need for supporting materialin most instances. There are some structures that may require or benefitfrom additional support, and so the present invention accommodates suchoptions. Third, systems configured in accordance with the presentinvention have the ability to print at a very high rates since thejetting and building take place in two different areas and those processcan be performed simultaneously. The main constraint on printing speedis either the curing process or the negative printing time, but timingsof these individual processes are not additive, meaning that the overallprint speed is not limited by an additive combination of the curing timeand the negative printing time. There are also fewer limitations for theUV light source used in curing than in conventional 3D printingprocesses, since the curing process is not digital.

The negative printing unit can be a laser assisted deposition/laserdispensing system with a pulsed laser having enough energy to jet thenegative image of the material from the film surface to the recoveryunit. The laser can be a UV, IR, CO₂, or any other laser.

If the printing unit is a laser assisted deposition/laser dispensingsystem, a uniformly coated substrate has an important role in therobustness of the system. Therefore, an additional coating system isadded before the printing unit. This coating system can be a traditionalcoating system, like a coating system based on micro gravure or slot diecoater or a roller coating system. It can also be a screen-printingbased coating system, a dispenser, or an inkjet system. In oneembodiment of the invention, the coating system can be based on asyringe and gap system as shown in FIG. 4 . In such a system 400,material 402 is dispensed from a syringe 404 to a substrate 406 (e.g.,by an air or mechanical pump that drives the material from the syringeonto the substrate) and the coated substrate 408 is moved (e.g., bymotor-driven rollers or other actuators) towards and through awell-defined gap 410. The gap can be defined by blades or other kind ofbarrier, as shown in FIG. 4 , or by two cylinders (e.g., rollers) spacedclose together.

After passing through the gap 410, a uniform layer 412 of material isformed on the substrate and the laser assisted deposition/laserdispensing system 414 can jet material from the coated substrate to amaterial recovery system. From the laser assisted deposition/laserdispensing system 414, the coated substrate 416 is passed to the curingstation 418, where it is brought into contact with a receiving substrate420 in the presence of a UV light and/or heat, thereby curing thematerial to form a new layer of the article being fabricated.

In other embodiments of the invention, the coating system may include ascreen-printing module where the printed substrate is coated on a screenor stencil of film with well-defined holes and, using a blade or asqueegee, the material is transferred to a substrate in a soft or hardengage. Alternatively, the coating system may include a dispenser or aninkjet head to print the material onto a carrier substrate. Or thecoating system may be a gravure or micro-gravure system that coats asubstrate with a highly uniform layer of material. In still furtherembodiments of the invention, the coating system may be a slot-diesystem that coats a substrate with a highly uniform layer of material.Or the coating system may be a roller coating system that coats asubstrate with a highly uniform layer of material.

In any of these and/or other embodiments of the invention, the coatingsystem may be disposed inside of a closed cell with a controlledenvironment (temperature, pressure, etc.) to prevent evaporation ofsolvent from the printed material or to prevent material oxidation,thereby helping to prolong the pot life of the material.

In some embodiments of the invention, the coating system contains morethan one material. This creates the possibility for printing a pluralityof materials onto an intermediate substrate (e.g., a film such assubstrate 406 in FIG. 4 ) in a controlled sequence, making it possibleto print more than one material onto a final substrate (e.g., receivingsubstrate 420 in FIG. 4 ).

In one embodiment of the invention, the intermediate substrate of thecoating system is translatable forwards and backwards (from thestandpoint of applying material to the intermediate substrate) in acontrolled manner, while opening the gap between the coater rollers,creating the possibility for recoating the same area of the intermediatesubstrate with the printed material multiple times without contaminationto the rollers. Such a process also reduces (or eliminates) the amountof intermediate substrate consumed during the initial printing process,preventing waste.

In some embodiments, after a current uniform layer of material coated onthe intermediate substrate has been consumed (fully or partially) byprinting in the printing unit, the intermediate substrate may loop backto the coating system for recoating or translate back to the coatingsystem for application of a new uniform coated layer for the nextprinting process.

The film (or other intermediate substrate) used for printing can be asubstrate that is transparent at the laser wavelength with or without ametal (or other) coating. Examples of such a film (substrate) are PET,BOPP, PI, etc. The film may be coated with a metal or polymer coatingwith additive(s) that adsorb at the laser wavelength and createtransparent areas digitally with exposure to the laser negative jettingsystem.

Among the materials for printing that may be used in systems configuredin accordance with the invention are any liquid or paste materials.However, the benefits of the present systems are chiefly present whenhighly viscous materials that cannot be printed properly in highresolution by other methods are employed. For example, UV-/visiblelight-cured material formulations and UV-cured monomers and polymers ofviscose or sensitive materials can be printed using systems configuredin accordance with the invention. Other materials that can be printedwith systems configured in accordance with the invention are acrylates,epoxies, urethanes, adhesives, pastes, and inks using either UV curingor heat curing. Still further materials that can be printed with systemsconfigured in accordance with the invention are UV-cured monomers andpolymers with additives such as ceramics, metals, organic additives,fiber reinforcement, etc. Also, materials such as UV-cured waxes, low orhigh viscosity materials that are cured or even partially cured bylight, epoxy based, urethane based, or silicone family materials with orwithout UV curable ends, where the reaction is initiated by heat orother catalyst (Pt, OH, etc.), ceramic and metal pastes, and solderpastes, bio-compatible materials, and thermoplastic materials (at roomtemperature or at elevated temperatures with adjustment of theenvironment temperature) can all be printed with systems configured inaccordance with the invention. Possible basic formulations andmechanisms can use monomers and polymers of acrylate, epoxy, urethane,or other UV or light sensitive materials with a light sensitiveinitiators or/and co-initiators or sensitizers, for example:acetophenones, thioxanthones, phosphine oxides, iodonium and sulfoniumsalts, etc.

FIG. 2 shows a system 200 configured in accordance with one embodimentof the invention. In this system, material 202 is first dispensed onto atransparent substrate 204 by a coating system 206, for example one usinga syringe and gap system, as discussed above. The material-coatedsubstrate 208 is provided to a negative printing unit 210 in which anegative image of the layer to be added to the sample is created byeliminating (e.g., via laser jetting) excess material (i.e., that partof the coated material that will not be added to the sample) from thecoated substrate. As illustrated, this excess material may be collectedby a material reuse system 212 and provided back to the coating system206 for reuse. As shown in this view, the remaining material 214 on thecoated substrate is provided to a curing system (e.g., a UV curingsystem) 216 and/or an imaging system on its way to the sample buildingunit 218 where UV curing and/or drying can be used during contact withthe sample 220. By curing/drying the material while it is in contactwith the sample (that is, previously formed portions of the articleunder fabrication, which are disposed on a receiving substrate 222), thesample's next layer is printed directly thereon. A sample release system224 then effects release of the sample 220 from the transport substrate204.

FIGS. 3 a-3 m illustrate in detail various steps involved in the overallprinting process. Referring first to FIG. 3 a , the negative jettingprocess 300 is illustrated. A layer 302 of material has been coated onan intermediate substrate (e.g., a film or foil) 304. A laser 306 isused to jet the negative of the image (of the next layer to be printedto the sample) from the coated substrate using the material's or thecoated metal film's laser absorption properties. The jetted material 308is collected 310 in a material recovery unit 312 (or units, if severalmaterials are in use) and the material can be reused later (FIGS. 3 aand 3 b ). Only segments of the image material 314 stay on the film 304for further use (FIG. 3 c ).

Optionally, as shown in FIG. 3 d , the image material 314 on the filmcan be exposed to low power UV light 326 or temperature before contactwith the sample. Because some materials, mostly liquid ones, needenhanced definition of image material boarders before such contact,e.g., to avoid a severe reduction in printing resolution, this procedureallows the boundaries of the portions of material image 314 to be welldefined. In such a process, a UV partial curing station 318 may includea gas diffusion system 320 for introducing an inert gas (e.g., Ar, CO₂,He, Ne, etc.) 322 into a workspace 324 in which UV light 326 from the UVlight source 316 will be incident upon the material layer 314. The inertgas flows in from one or more gas inlets 328 and out through a diffuser330 towards the workspace 324. A gas pressure homogenizer may be used toensure constant pressure throughout the system.

Preferably, the intermediate substrate 304 is coated with a thin metalfoil 332, for example, a 20 nm thick layer of Ti. The layer of metalfoil will substantially reduce transmission of the UV light 326 wherepresent, ensuring that only the edge of the material layer 314 near thearea of contact with the intermediate substrate 304 is cured orpartially cured. As an example, a 20 nm thick layer of Ti will transmitonly approximately one tenth of the UV light 326 that an unprotectedarea of the intermediate substrate 304 will transmit. In areas where themetal foil has been eliminated, e.g., as by laser ablation or otherprocess, the UV light 326 will be incident upon the edges of thesegments of the material layer 314, again ensuring that it is theseedges only that are cured or partially cured. As an additional safeguardto prevent unwanted curing or over curing of the segments of thematerial layer 314, the gas diffusion system 320 may be made of anon-reflective material so that UV light 326 is not reflected towardsthe segments of the material layer 314.

The presence of inert gas 322 pumped through the diffuser purges anyoxygen from the workspace 324. The thickness of this workspace region isrelated to the gas pressure as it is forced through the diffuser 330.With the segments of material layer 314 maintained in the area of theworkspace from which oxygen has been purged, the UV curing system thencures the bottom and edges of these segments through exposure to UVlight 326 from the UV light source 316.

FIGS. 3 e and 3 f provide before and after views of the contact betweenthe film 304 (i.e., the segments of coated material 314 on the film) andthe sample, while FIG. 3 g illustrates the UV exposure and building ofthe sample. This stage may use either UV exposure or exposure to hightemperature (a coated polyimide film such as Kapton can be used in suchcases) to effect transfer of the material to the sample. As shown, thefilm 304 is brought into an area at which the receiving substrate 334 ispresent, and the receiving substrate (or an existing layer of thesample, if present) is brought into contact with the segments of coatedmaterial 314 on the film (e.g., by raising a state on which thereceiving substrate is present). Then, the segments of coated material314 are cured through exposure to UV light 336 from a UV light source338. This may be the same or a different UV light source as mentionedabove. The exposure to the UV light 336 (and/or heat) cures the segmentsof coated material to form segments of a new layer 340 of the sample(i.e., the object undergoing fabrication).

After curing, the sample remains connected to the film 304 (through thesegments of the newly cured layer 340). Therefore, a release mechanismis preferably provided. To that end, the laser itself (used for thenegative printing) 306 can be used as a sample release unit since themetal coat of the film 304 is still beneath the now-cured material andcan be used for laser wavelength absorption and sample release as shownin FIGS. 3 h-3 j . The laser 306 irradiates the positioned at which thesegments of the newly cured layer 340 are present, permitting suchseparation. The laser can also be used for cleaning the sample of metalresidues 342 that may have detached from the film 304 during samplerelease (FIG. 3 k ), leaving a clean, cured layer 340 present on thesample (FIG. 3 l ). The result 350 of printing several layers 340 ispresented at FIG. 3 m.

FIGS. 4-7 show examples of configurations of systems for performing themethods of the present invention. In one embodiment of the invention,only one material is provided for printing only one layer. FIG. 4illustrates such a configuration: Material 402 is coated on film 406; alaser system 414 removes the image negative, and multiple samples 420are moved into contact with the film 406 sequentially. The material 416is cured during contact, and a new sample replaces the old one.

FIG. 5 illustrates a 3D version of the configuration shown in FIG. 4 .This time, the same sample 520 is brought into repeated contact with thefilm 406 and each time a new layer 522 a, 522 b, etc., is added(printed) to the sample. The curing takes place during contact of thetop of the sample with the material in a new layer 524 on the film.However, it is important to note that if there is no direct contactbetween the material on the film and the sample, the transfer from thefilm to the sample will not occur. Therefore, the transfer depends onthe area of each unit of material on the film and the surface structureof the sample.

One way to overcome this issue is to add a support material 602 thatwill come in contact with the film 406 and therefore will transfer allthe material 524 on the film to the sample. FIG. 6 illustrates the useof support material 602 in order to collect all the material from thefilm to the sample.

FIG. 7 illustrates the use of an optional unit 702 for 3D negativeprinting with a support material. The optional unit 702 injects thesupport material 704 mechanically (e.g., via a syringe 706) to even thesample height that will be in contact with the film 406 during curing.The sample 520 is moved back and forth between the curing position 710and the support injection position 712 between layers.

An even more advanced configuration of a system configured in accordancewith embodiments of the invention is one for the 3D printing of multiplematerials. In such cases, several coating units are placed to providedifferent materials to the transfer film(s) and different materials arecoated on the film or films, negative images for each respectivematerial are removed from the film(s), and the materials are broughtinto contact with the sample and transferred thereto. FIG. 8 a-8 billustrate before and after views of the contact between a substrate 802that includes a second material 804 and a sample 334 that alreadycontains the first material 314. The negative images of the differentmaterials are compatible so that they can co-exist in the same layer.

The film itself could be a transparent anti-stick foil. For example,PTFE or PFE or other anti-stick foils can used in order to ensure theeasy release of the sample from the film after curing. FIGS. 9 a-9 billustrate before and after views of the release process based onanti-stick properties of a film 902. That approach for sample releasecould be a complementary approach to the laser release mechanismmentioned above or the only release mechanism to be used.

Yet another approach for sample release could be a dominantly mechanicalapproach. FIG. 10 illustrates a mechanical release system 1002 that canwork with or without the formerly mentioned release mechanisms. Any ofseveral mechanical approaches can be used. For example, a low anglerelease towards a “Y”-axis, by moving the film 406 at a small angle awayfrom the sample 1004, can be used. Alternatively, two Z-axes, one for aframe (holding the film 406) and one for the sample 1004 may be used.Another approach would be to use acoustic vibrations to release the film406 from the sample 1004.

FIG. 11 illustrates one additional feature of a system configured inaccordance with embodiments of the invention: the material reuse system1102. In order to reduce waste, the negative image printing can be doneabove a tray or other vehicle that collects unused material and injectsit back into the syringe 404 of the coating unit.

Not shown in the above-described views are one or more units thatcontrol the operation of the various systems. Persons of ordinary skillin the art will appreciate that such units, often called controllers orsimilar names, are processor-based units that are programmable to carryout the above-escribed processes by issuing signals to elements of thecoating system, the negative printing unit, the material reuse system,the curing system(s) and the sample release system. In some cases, thesesignals will actuate end effectors, rollers, lasers, UV or IRlighting/heating systems, and other elements to carry out theabove-described tasks. Such a controller generally includes a processoror processors that execute(s) computer-readable instructions (i.e.,computer programs or routines) defining methods as described herein,which methods are instantiated and run on non-transitorycomputer-readable media. Such processes may be rendered in any computerlanguage and executed on any suitable programmable logic hardware.Processor-based controllers upon or with which the methods of thepresent invention may be practiced will typically include a bus or othercommunication mechanism for communicating information; a main memory,such as a RAM or other dynamic storage device, coupled to the bus forstoring information and instructions to be executed by the processor andfor storing temporary variables or other intermediate information duringexecution of instructions to be executed by the processor; and a ROM orother static storage device coupled to the bus for storing staticinformation and instructions for the processor. A storage device, suchas a hard disk or solid-state drive, may also be included and coupled tothe bus for storing information and instructions. The subject controllermay, in some instances, include a display coupled to the bus fordisplaying information to a user. In such instances, an input device,including alphanumeric and/or other keys, may also coupled to the busfor communicating information and command selections to the processor.Other types of user input devices, such as cursor control devices mayalso be included and coupled to the bus for communicating directioninformation and command selections to the processor and for controllingcursor movement on the display.

The controller may also include a communication interface coupled to theprocessor, which provides for two-way, wired and/or wireless datacommunication to/from the controller, for example, via a local areanetwork (LAN). The communication interface sends and receiveselectrical, electromagnetic, or optical signals which carry digital datastreams representing various types of information. For example, thecontroller may be networked with a remote unit to provide datacommunication to a host computer or other equipment operated by a user.The controller can thus exchange messages and data with the remote unit,including diagnostic information to assist in troubleshooting errors, ifneeded.

Thus, methods and apparatus for the fabrication of solidthree-dimensional objects from liquid polymerizable materials at highresolution have been described.

What is claimed is:
 1. A system, comprising a coating system configuredto coat a substrate with a uniform layer of liquid polymerizablematerial and provide the coated substrate to a negative printing unit,the negative printing unit configured to remove portions of the liquidpolymerizable material from the coated substrate and provide a resultingversion of the coated substrate with remaining segments of the liquidpolymerizable material to a sample building unit that is spatiallyseparated from the negative printing unit, the sample building unitconfigured to engage the coated substrate with the remaining segments ofthe liquid polymerizable material that represents an image of a layer ofan article under fabrication with a sample and cure said remainingsegments of the liquid polymerizable material with ultra-violet (UV)light when the remaining segments of the liquid polymerizable materialare in contact with the sample.
 2. The system of claim 1, wherein thecoating system includes one of: a screen-printing module configured tocoat the liquid polymerizable material on a screen or stencil of filmwith well-defined holes using a blade or a squeegee, and further tosubsequently transfer the liquid polymerizable material to the substratein a soft or hard engage; a dispenser configured to print the liquidpolymerizable material onto the substrate; an inkjet head configured toprint the liquid polymerizable material onto the substrate; a gravure ormicro-gravure system configured to coat the substrate with the uniformlayer of the liquid polymerizable material; a slot-die system configuredto coat the substrate with the uniform layer of the liquid polymerizablematerial; a roller coating system configured to coat the substrate withthe uniform layer of the liquid polymerizable material; and a syringe ofthe liquid polymerizable material, a pump that drives the liquidpolymerizable material from the syringe onto the substrate, and anactuator which is configured to transport the coated substrate towardsand through a gap between rollers or knifes to create the uniform layerof the liquid polymerizable material on the substrate with a thicknessthat is defined by the gap.
 3. The system of claim 2, wherein thecoating system is inside a closed cell with a controlled environment. 4.The system of claim 2, wherein the coating system is configured to coatthe substrate with more than one liquid polymerizable material.
 5. Thesystem of claim 2, wherein the coating system includes the gap and isconfigured to translate the substrate bidirectionally through thecoating system while adjusting a width of the gap.
 6. The system ofclaim 2, wherein the liquid polymerizable material is a UV light curablematerial.
 7. The system of claim 2, wherein the negative printing unitis a laser-based system that contains a laser configured to jet materialfrom the coated substrate to a material reuse system.
 8. The system ofclaim 2, wherein the substrate is one of: a continuous transparent filmsubstrate, a transparent film substrate coated by a metal layer, or atransparent film substrate coated by a metal layer and a dielectriclayer.
 9. The system of claim 2, further comprising a support materialaddition unit configured to inject support material on the sample.